Foam spring mattress configured with variable firmness

ABSTRACT

A method includes selecting an arrangement of foam springs, the arrangement that matches user-selected firmness requirements; attaching foam springs to a foam panel in a removable, replaceable manner; and inserting the foam springs and the foam panel into a containment facility. A mattress includes foam springs; a foam panel to which an arrangement of the foam springs is attached in a removable, replaceable manner; a containment facility within which the foam springs and the foam panel are disposed; and a side rail with indentations within which sides of at least some of the foam springs are disposed. The mattress may also include a fabric webbing, attached to the containment facility, within which some of the foam springs are disposed in a removable, replaceable manner; and an attachment device attaching together at least two of the foam springs.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/080,701 filed on Apr. 6, 2011, which is a continuation of U.S.application Ser. No. 11/876,562 filed on Oct. 22, 2007, which is acontinuation-in-part of U.S. application Ser. No. 11/847,011 filed onAug. 29, 2007, which claims the benefit of U.S. Provisional App. No.60/823,891, filed Aug. 29, 2006. Each of the foregoing applications isincorporated herein by reference in its entirety.

BACKGROUND

1. Field

This invention relates to a method and system of providing a mattressand more particularly, to a mattress using a plurality of foam springsto provide comfort and support to the user of the bed.

2. Background

Consumers, manufacturers, and distributors may each individually or asgroups have many different opinions of the type of a bed and bedfirmness that may provide for a comfortable resting or sleepingcondition. There are many different types of beds and firmnesses tochoose from when deciding on a bed to purchase. In an attempt to provideusers with comfortable beds, bed manufacturers may use metal springs,foam layers, solid foam blocks, water, air, or other means to providevarious types of firmness to a user. These different types of beddingmaterials may be used individually or in combination. Beds may beavailable in various firmnesses using a combination of springs, foamsand materials in various combinations may provide for firmer or lessfirm support to the user. However, even though great effort has beendedicated to making a mattress that provides good support and comfort,the present solutions are inadequate and a need exists for an improvedmattress.

SUMMARY

In one aspect, a method of foam spring configuration that is disclosedherein includes selecting an arrangement of foam springs, thearrangement that matches user-selected firmness requirements; attachingfoam springs to a foam panel in a removable, replaceable manner; andinserting the foam springs and the foam panel into a containmentfacility. The method of foam spring configuration may include insertingat least some of the foam springs into indentations of a side railadapted to receive, hold, and release sides of the foam springs.Inserting may include zipping closed the containment facility afterinserting the foam springs and the foam panel into the containmentfacility. The method of foam spring configuration may further includeselecting the arrangement includes outputting a schematic showing thefoam springs placed within the containment facility. Inserting the foamsprings into the containment facility may include individually insertingthe foam springs into an opening in a fabric webbing of the containmentfacility, the fabric webbing securing the foam springs, in a removableand replaceable manner, in predetermined locations within thecontainment facility. The method of foam spring configuration mayinclude using an attachment device to attach together at least two ofthe foam springs. The attachment device may include a snap, and whereinusing the attachment device includes snapping together the at least twoof the foam springs. The attachment device may include a hook and loopfastener, and wherein using the attachment device includes pressingtogether the at least two of the foam springs. The attachment device mayinclude a glue, and wherein using the attachment device includes gluingtogether the at least two of the foam springs.

In one aspect, a mattress that is disclosed herein includes foamsprings; a foam panel to which an arrangement of the foam springs isattached in a removable, replaceable manner; a containment facilitywithin which the foam springs and the foam panel are disposed; and aside rail with indentations within which sides of at least some of thefoam springs are disposed. The mattress may include a schematic showingthe arrangement. The mattress may include a fabric webbing, attached tothe containment facility, within which some of the foam springs aredisposed in a removable, replaceable manner. The mattress may include anattachment device attaching together at least two of the foam springs.The attachment device may include a snap. The attachment device mayinclude a hook and loop fastener. The attachment device may include aglue.

In one aspect, a mattress that is disclosed herein includes foamsprings; a foam panel to which an arrangement of the foam springs isattached in a removable, replaceable manner; a containment facilitywithin which the foam springs and the foam panel are disposed; a siderail with indentations within which sides of at least some of the foamsprings are disposed; a fabric webbing, attached to the containmentfacility, within which some of the foam springs are disposed in aremovable, replaceable manner; and an attachment device attachingtogether at least two of the foam springs. The attachment device mayinclude a snap. The attachment device may include a hook and loopfastener. The attachment device may include a glue.

These and other systems, methods, objects, features, and advantages ofthe present invention will be apparent to those skilled in the art fromthe following detailed description of the preferred embodiment and thedrawings. All documents mentioned herein are hereby incorporated intheir entirety by reference.

BRIEF DESCRIPTION OF FIGURES

The systems and methods described herein may be understood by referenceto the following figures:

FIG. 1 shows a block diagram of the bed facility and related components.

FIG. 2 shows three embodiments of foam spring configurations.

FIG. 3 shows another embodiment of a foam spring configuration.

FIGS. 4A-4M show different shapes embodiments of a foam spring.

FIGS. 5A-5D show different embodiments of exterior and interior shapesfor a foam spring.

FIGS. 6A-6C show embodiments of foam springs combined with an attachmentfacility.

FIGS. 7A-7B show embodiments of foam springs combined with an attachmentfacility.

FIG. 8 shows an embodiment of different attachment facilities forindividual foam springs.

FIG. 9 shows an embodiment of foam springs being grouped into regionswith a containment facility.

FIG. 10 shows an embodiment of a set of foam spring regions.

FIG. 11A shows an embodiment of foam springs associated with a bottomfoam panel.

FIG. 11B shows an embodiment of foam springs associated with a top foampanel.

FIG. 11C shows an embodiment of foam springs associated with a foampanel including vertical locators.

FIG. 11D shows an embodiment of foam springs associated with a foampanel including horizontal and vertical locators.

FIG. 11E shows a foam side rail including indentations for receiving,holding, and releasing foam springs.

FIG. 12 shows an embodiment of a general foam spring configuration in acontainment facility.

FIG. 13 shows an embodiment of foam springs in regions within acontainment facility.

FIG. 14 shows an embodiment of different firmness foam springs in acontainment facility.

FIG. 15 shows an embodiment of different firmness foam springs in acontainment facility.

FIG. 16 shows an embodiment of foam springs including magnets in acontainment facility.

FIG. 17 shows an embodiment of foam springs including activated carbonin a containment facility.

FIG. 18 shows an embodiment of foam springs including tourmaline in acontainment facility.

FIG. 19 shows an embodiment of a pneumatic and/or hydraulic facilitycoupled with a chamber.

FIG. 20 shows an embodiment of a pneumatic and/or hydraulic facilitycoupled with sets of chambers.

FIGS. 21A-21D shows an embodiment of using foam springs with metalsprings in a containment facility.

FIG. 22 shows an embodiment of accessing foam springs installed within acontainment facility.

FIG. 23 shows an embodiment of accessing foam springs installed within acontainment facility.

FIG. 24 shows an embodiment of foam springs within pillows.

FIG. 25 shows an embodiment of foam springs within a chair cushion.

FIG. 26 shows an embodiment of foam springs within an automobile seat.

FIG. 27 shows a display screen for a foam spring orientation softwareapplication.

FIG. 28 shows an input screen for a foam spring orientation softwareapplication.

FIG. 29 shows an input screen for a foam spring orientation softwareapplication.

FIG. 30 shows an input screen for a foam spring orientation softwareapplication.

FIG. 31 shows an output screen for a foam spring orientation softwareapplication.

FIG. 32 shows an output screen for a foam spring orientation softwareapplication.

DETAILED DESCRIPTION OF FIGURES

A user may have an overall bed comfort requirement for their overallbody, but may also have requirements for localized body comfort. Theuser may have a unique situation that may require various comfort levelswithin a bed. For example, the user may desire a general medium firmnessfor the bed but may have additional requirements of firmer support inthe users back area to provide additional back support for total bodycomfort.

A bed that may have interchangeable foam springs may allow the user tointerchange different foam spring firmnesses to provide firmnessdifferences that may compensate for local body areas requiring differentsupport than the overall bed. To aid in the placement of the variousfoam spring firmnesses there may be facilities to hold the foam springsin the required locations and a method of determining where to place thevarious foam springs to provide the users desired comfort. There may bea plurality of methods to place the different foam spring firmness intothe bed that may include trial iteration, a questionnaire, a softwareapplication, or the like. The plurality of foam spring placement methodsmay be performed by the user alone or may be done in combination with abed enterprise, service enterprise, manufacturer, or the like.

One of the goals of the customizable firmness bed may be to provide theuser with an apparatus and method of creating a bed with different localfirmnesses that may compensate for different comfort requirements theuser may have. The user may require less firmness in one location of thebed while also requiring firmer support in other locations of the bed.As described below, methods and systems are described that may allow theplacement of individual firmness foam springs in a bed to provide totalcomfort requirements to a user.

Another goal may be to provide a method of determining where to placethe various firmness foam springs within the bed to meet the usersrequirements. As described below, the user may provide input for thetype or foam spring and foam spring firmness that may be required and afoam spring orientation may be determined using the users input.

Referring now to FIG. 1, a block diagram of a bed facility 102 andassociated components is shown. In embodiments, the bed facility 102 mayinclude a containment facility 104, attachment facility 120, regions 122of foam springs, and a plurality of foam springs 108. The foam springs108 may also include materials that may provide health benefits to theuser such as activated carbon 110, tourmaline 112, and magnets 114.Additionally, there may be a foam spring orientation application 118 toaid in the placement position of the plurality of foam springs 108. Inan embodiment, the containment facility 104 may have the shape of a bedmattress with a bottom, top, and sides and may provide the shape inwhich the foam springs 108 may be placed. In an embodiment, the foamsprings may be oriented into different regions 122 where the differentregions may contain different firmness foam springs 108. The attachmentfacility 120, as will be described below, may provide openings in whichthe foam springs 108 may be placed. The attachment facility 120 openingsmay provide a pattern of openings to allow foam springs of variousfirmness to be placed within the containment facility 104. As shown inFIG. 1, the plurality of foam springs 108 may include firmness 1,firmness 2, through firmness N to provide various firmnesses within thebed facility 102. The foam spring orientation application 118 may beused by the user, sales enterprise, manufacturer, or the like todetermine where the plurality of foam springs 108 should be placed tomeet the users comfort requirements.

A bed facility 102 may be any type of bed that may provide a comfortableposition for a user to rest, sleep, sit, convalesce, or the like. Thebed facility 102 may include a standard bed, an adjustable bed, or thelike. The bed facility 102 may be in any shape or size that may includea crib bed, twin bed, full size bed, queen size bed, king size bed, orthe like. In an embodiment, the bed facility 102 may typically include amattress, box spring, support frame, and the like. In an embodiment, themattress may include a material top layer (e.g. foam or material),material bottom layer, springs, foam layers, and the like.

In an embodiment, a standard non-adjustable bed may be any bed thatmaintains a single rigid position that may not be capable of changingits shape or position. Additionally, the non-adjustable bed may be anyrigid shape that may have a non-flat configuration.

In an embodiment, an adjustable bed may be a type of bed that is capableof adjusting at least one aspect of the bed shape such as a headsection, a foot section, leg section, a torso section, or the like. Inan embodiment, there may be a control interface that a user may use toadjust the position of at least one aspect of the bed.

In an embodiment, the foam springs 108 may be any type of soft foam thatmay include latex foam, urethane foam, visco-elastic foam, polyurethanefoam, or the like. In an embodiment, the foam springs 108 may be usedfor bedding, pillows, chairs, couches, or the like. In an embodiment,the foam springs 108 may be considered a foam support for the bedfacility 102.

In an embodiment, the foam springs 108 may be made of the solid foammaterial but may additionally have interior openings, exterior openings,interior and exterior opening, or the like. The openings may not beimportant to the firmness of the foam spring 108 but may be useful formanufacturability of the foam spring, providing space for added foamspring movement, contain health related materials, and the like.

In an embodiment, a mattress outer case may be a part of the bedfacility 102 mattress that provides the volume space to place the foamsprings 108. In an embodiment, the mattress outer case may be themattress, a separate bed structure from the mattress, or the like. Themattress outer case may have a shape that is substantially the same asthe bed facility 102. In an embodiment, the foam spring 108 may have aheight that may equal to the height of the mattress outer case, may be aportion of the height of the mattress outer case, may have a heightgreater than the mattress outer case, or the like. In an embodiment, thecross section of the foam spring 108 may have any shape that may includea round shape, a square shape, a hexagon shape, an octagon shape, a starshape, an oval shape, or the like. In an embodiment, a plurality of foamsprings 108 may be contained within the mattress outer case. Theplurality of foam springs 108 may be all the same shape, a combinationof shapes, or the like. In some cases, the foam spring 108 shapes may becombined to provide for spaces between the foam springs 108 that mayallow the foam springs 108 to have freedom of motion. For example, theplurality of foam springs 108 may be all circle shaped or a combinationof circle and oval shaped foam springs 108 to provide spaces between thefoam springs 108 to allow motion areas for the foam springs 108. Inother cases, it may be desired for the foam springs 108 shapes to beselected where the foam springs 108 are in close contact with each otherto allow each of the foam springs 108 to support the adjacent foamsprings 108. For example, the plurality of foam springs 108 may be allsquare foam springs 108 that contact adjacent foam springs 108 on allfour sides; this may provide support to the foam spring 108 and all theadjacent foam springs.

In an embodiment, the plurality of foam springs 108 contained within themattress outer case may have a plurality of different firmnesses. In anembodiment, the foam spring 108 firmness may be defined by anindentation load deflection (ILD) value, indentation force deflection(IFD) value, foam density, or the like. IFD, and in a similar mannerILD, is defined as the amount of force, in pounds, required to indent afifty square inch, round surface into a foam material a certainpercentage of the foam material total thickness. IFD may be specified asthe number of pounds at a specific deflection percentage for specificheight foam. For example, the IFD for a certain foam may be defined as25 pounds/50 in² at a 25% deflection on a four inch thick piece. In anembodiment, the IFD may be influenced by the thickness of the foammaterial, the size of the material, and the like. For some types ofmaterials, such as latex foam, the ILD value may correlate with thedensity of the material used. For others, the ILD may be less dependent,or even independent, of the density of the material used.

The firmness may also be measured or described by the density of thefoam, in pounds per cubic foot, kilograms per cubic meter, or some otherrelevant standard. Although the density may not be a direct measurementof firmness, it may have a direct relationship to firmness. For example,a 110 kg/m3 density barrel may be firmer than a 95 kg/m3 barrel and the95 kg/m3 barrel may be firmer than a 80 kg/m3 density barrel, and thelike.

In an embodiment, the plurality of foam springs 108 may be configuredwithin the mattress outer case to provide localized variable firmnessesfor the bed facility 102. In an embodiment, the firmness of a bedfacility 102 may be varied to provide comfort for a user that may beexperiencing discomfort as a result of an accident, arthritis, surgery,chronic conditions, a neck condition, a knee condition, a sleepdisorder, a disease, or the like. In some cases, the discomfortexperienced by the user may not be static but may be part of a changingcondition that may have the user experiencing more or less discomfortover time.

In many cases the discomfort the user may experience may be a localdiscomfort such as lower back pain, hip pain, neck pain, shoulder pain,and the like where it may be advantageous to have different firmness inthese areas to provide an improved resting comfort in the localposition. For example, the user may experience lower back pain and theplurality of foam springs 108, with a certain firmness, may beconfigured to provide less firm or firmer support in the lower back areato help provide a comfortable resting position.

In an embodiment, the user's discomfort may change over time, and theplurality of foam springs 108 may be modified to compensate for thechanging user condition. For example, if the user is suffering fromlower back pain, the initial foam spring 108 configuration may providefirmer support in the area of the lower back to position the back forimproved healing. Over time, the user's lower back may improve and thefoam springs 108 firmness in the area of the lower back may be modifiedby gradually providing less firm support until the form spring 108firmness is the same as the remainder of the bed facility 102.

In an embodiment, when considering the location to place the variousfoam spring 108 firmnesses, the user's physical characteristics (e.g.height, weight, body shape, gender) may be considered for the properplacement and firmness of the foam spring 108. For example, theplacement for the foam springs 108 for a user's lower back may beinfluenced by the user's height, typical sleeping position, size of thebed, shape of the bed, location the user sleeps on the bed (e.g. towardsthe head or foot of the bed), and the like.

It may be understood that the foam spring 108 configuration may bevaried to account for more than one user condition of discomfort. Forexample, a user may have more than one body location that is effected byarthritis. The plurality of foam springs 108 may be configured toprovide comfortable resting conditions to any or all of the bodylocations that the user desires discomfort relief. As these conditionsmay improve or worsen over time, the user may be able to change the foamspring 108 configuration, change the firmness of the foam spring 108 incertain bed facility 102 locations, or the like. As another example, auser may be experiencing discomfort from a chronic condition (e.g.arthritis) and a short-term condition (e.g. surgery). As the short termcondition improves, the foam springs 108 in the short-term location maybe changed as needed to provide the user with the desired comfort. In asimilar manner, as the chronic condition may change with time, the foamsprings 108 may be changed in these locations to provide the bestcomfort position for the user.

In another embodiment, the springs used within the bed facility 102 maybe pneumatic or hydraulic springs that may be have adjustable firmnesssettings. A bed facility 102 may have a pattern of pneumatic orhydraulic springs that may be orientated using a containment facility104. In an embodiment, the user may be able to adjust the individualfirmnesses of the pneumatic or hydraulic springs to meet the comfortrequirements of the user. In an embodiment, there may be a computerdevice interface where the user may be able to indicate the requiredfirmness for certain locations of the bed facility 102. In anembodiment, the computer device may be a desktop computer, laptopcomputer, server, webserver, personal digital assistant (PDA),smartphone, handheld computer, or the like. The computer devices mayinclude connections to a network for accessing other computer devicesthat may store or manage bed facility 102 information. In an embodiment,the networks may include a WAN, LAN, Internet, intranet, peer-to-peer,or other network connecting computer devices. In an embodiment, thecomputer device and networks may be wired or wirelessly connected. In anembodiment, using the network, the user may be able to access computerdevices on the network to receive spring firmness settings. For example,the user may access the Internet from the computer device and maydownload a particular set of spring firmness settings that may match adesired comfort requirement. In an embodiment, the computer deviceinterface may show a grid substantially the same as the orientation ofthe pneumatic or hydraulic springs where the user may be able toindicate the firmness of the individual springs, groups of springs,zones of springs, areas of springs, the entire bed facility 102, or thelike. In an embodiment, the user may work with the computer deviceinterface using a keyboard, mouse, joystick, touch screen, or otherinput device. In an embodiment, based on the user's indications, thecomputer device interface may control the pressure of the individualpneumatic or hydraulic springs to provide the desired comfort. In anembodiment, there may be preset firmness configurations that may beselected on the computer device interface; the preset configurations maybe user set, historical settings saved by the computer device, preset atthe manufacturer, preset at the bed facility 102 enterprise, or thelike. In an embodiment, the user may change the firmness configurationas often as the user requires.

In addition to varying the foam spring 108 firmness in a bed facility102, the foam spring may also contain additional health benefitmaterials that may provide an improved healing environment. In anembodiment, the additional health benefit materials may includeactivated carbon, tourmaline, magnets, and the like. In an embodiment,the additional health benefit materials may be used individually or incombination within the foam spring 108, the bed facility 102, or thelike.

Activated carbon 110 is a material that has an exceptionally highsurface area that includes a large amount of micro porosity. Sufficientactivation for useful applications may come from the high surface areabut further chemical treatment may used to enhance the absorbingproperties of the activated carbon. Activated carbon attracts and holdscertain chemicals therefore reducing dust, odors, contaminates, and thelike from the area around the activated carbon. The contaminants may beattracted to and held (adsorbed) on the surface of the carbon particles.The characteristics of the carbon material such as particle size, poresize, surface area, surface chemistry, density, and hardness mayinfluence the efficiency of adsorption.

In an embodiment, as part of the foam spring 108 manufacturing process,the activated carbon 110 may be mixed with the foam spring 108 materialto provide an effective mixing of the activated carbon 110 into the foamspring 108. In an embodiment, the amount of activated carbon 110 in thefoam spring 108 may be dependent on the environment of the bed facility,user requirements, or the like. For example, a user that requires a lowdust environment may use foam springs 108 with increased activatedcarbon content.

In an embodiment, foam springs 108 that contain activated carbon 110 maybe all of the foam springs 108 within the bed facility 102, may be aportion of the foam springs 108 within the bed facility 102, may beplaced in zones in the bed facility 102 or the like.

In another embodiment, the activated carbon 110 may be added to the foamspring 108 as a separate filtering device. For example, the foam spring108 may have an opening, a pocket, a recess, a holding area, or the likewhere activated carbon 110 may be added. In an embodiment, the foamspring 108 manufacturer, bed facility 102 enterprise, user, or the likemay add the separate activated carbon 110 filtering device to the foamspring 108. In this embodiment, the activated carbon 110 may bereplaceable to provide a continual level of air filtration. In thisembodiment, the amount of activated carbon 110 that is used with the bedfacility 102 may be varied to provide a level of air filtration to theusers requirements.

Tourmaline 112 is a natural material that is a source of negative ionsand far infrared rays. Tourmaline 112 is believed to be useful forimprove circulation, to relieve stress, to improve mental alertness, andto strengthen immune system function.

In an embodiment, as part of the foam spring 108 manufacturing process,the tourmaline 112 may be mixed with the foam spring 108 material toprovide an effective mixing of the tourmaline into the foam spring 108.In an embodiment, the amount of tourmaline 112 may be adjusted for auser's requirements.

In an embodiment, foam springs 108 that contain tourmaline may be all ofthe foam springs 108 within the bed facility 102, may be a portion ofthe foam springs 108 within the bed facility 102, may be placed in zonesin the bed facility 102 or the like.

In another embodiment, the tourmaline 112 may be added to the foamspring 108 as a separate device. For example, the foam spring 108 mayhave an opening, a pocket, a recess, a holding area, or the like wheretourmaline 112 may be added. In an embodiment, the foam spring 108manufacturer, bed facility 102 enterprise, user, or the like may add theseparate tourmaline 112 device to the foam spring 108. In thisembodiment, the amount of tourmaline 112 that is used with the bedfacility 102 may be varied to provide a health benefit level to theusers requirements.

Magnets 114 are believed to be helpful for increased blood circulation,reducing inflammation, increased recovery speed from injuries, and thelike. In an embodiment, as part of the foam spring 108 manufacturingprocess, the magnets 114, magnetic material, or the like (magnets) maybe mixed with the foam spring 108 material to provide an effectivemixing of the magnets 114 into the foam spring 108. In an embodiment,the amount of magnets 114 in the foam spring 108 may be dependent on theuser requirements.

In an embodiment, foam springs 108 that contain magnets 114 may be allof the foam springs 108 within the bed facility 102, may be a portion ofthe foam springs 108 within the bed facility 102, may be placed in zonesin the bed facility 102 or the like.

In another embodiment, the magnets 114 may be added to the foam spring108 as a separate device. For example, the foam spring 108 may have anopening, a pocket, a recess, a holding area, or the like where magnets114 may be added. In an embodiment, the foam spring manufacturer, bedfacility 102 enterprise, user, or the like may add the separate magnet114 device to the foam spring 108. In this embodiment, the number oramount of magnets 114 that are used with the bed facility 102 may bevaried to provide the health benefits to the user's requirements.

In an embodiment, the pattern of magnet placement within the foam spring108, within the bed facility 102, a combination of placement within thefoam spring 108 and bed facility 102, or the like may be important tothe magnet health benefits received by the user. In an embodiment, amagnet orientation application may be used to determine the placement ofthe magnets within the foam spring 108, bed facility 102, and the like.In an embodiment, the magnets may be placed to provide an increasedmagnet influence to provide health benefits in certain user bodylocations. In an embodiment, the magnet orientation application maydetermine the location of magnets within each individual foam spring108. A user may answer questions that are input to the magnetorientation application; the questions may be completed interactivelywith the computer device. In an embodiment, the magnet orientationapplication may provide magnet orientation within the foam spring 108,the bed facility 102, magnet foam spring 108 within the bed facility102, and the like.

In an embodiment, the foam spring 108 may have an attachment facility120 on the outer surface of the foam spring 108 to provide a connectionto a containment facility 104; the containment facility 104 may be usedto maintain the orientation of the plurality of foam springs 108 withinthe mattress outer case. In an embodiment, the foam spring 108attachment facility 120 may be a geometric shape, a mechanicalattachment device, a direct attachment device, or the like. In anembodiment, the geometric shape may be additional shaped foam materialthat extends out from the outer surface of the foam spring 108, may be arecess in the outer surface of the outer surface of the foam spring 108,may be a combination of extended shape and recess of the outer surfaceof the foam spring 108, or the like that may be used to connect the foamspring 108 to the containment facility 104.

In an embodiment, the mechanical attachment may be a buckle, a snap, aclip, glue, and the like that may allow the foam springs to be joineddirectly together, used to connect to the containment facility 104, orthe like.

In an embodiment, the direct attachment device may be Velcro, tape,double stick tape, glue, elastic, or the like that may allow the foamsprings to be joined directly together, connected to the containmentfacility 104, or the like.

In an embodiment, the foam springs 108 may be connected together usingthe attachment device without the use of the containment facility 104.In this manner, the foam springs 108 may maintain orientation by beingconnected to at least one adjacent foam spring 108.

In an embodiment, the individual foam springs 108 may be encased withina cylinder of fabric where the fabric cylinder may provide theattachment device. In an embodiment, at least two fabric encased foamsprings 108 may be connected together in an orientation of foam spring108 firmnesses. In an embodiment, the fabric encased foam springs 108may be oriented using the same firmness foam springs 108, differentfirmness foam springs 108, or the like. In an embodiment, the individualfabric encased foam springs 108 may be connected using at least one ofglue, Velcro, tape, fabric bonding, snaps, clips, string, webbing, orthe like.

As an alternative fabric wrapping configuration, the foam springs may beonly partially encased in the fabric wrapping, such as 30%-40%. Similarto the fully fabric enclosed foam springs, the partially encased foamsprings may be connected using glue, Velcro, tape, fabric bonding,snaps, clips, string, webbing, or the like. In an embodiment, thepartially encased foam springs may allow the changing or moving of thefoam springs within the partial encasement and therefore may allow forfirmness changes to be made within the mattress.

In an embodiment, the fabric encased foam springs 108 may be orientatedand interconnected as a line of foam springs, as a circle of foamsprings 108, as a square of foam springs 108, as a rectangle of foamsprings 108, or the like. In an embodiment, at least one interconnectedfabric encased foam springs 108 may be configured into a bed facility102. For example, the bed facility 102 may include a rectangularinterconnected fabric encased foam springs 108 at the head and footzones while the shoulders and hip zones use circle interconnected fabricencased foam springs 108.

In an embodiment, the more than one interconnected fabric encased foamsprings 108 within a bed facility 108 may be all the same firmness,different firmnesses, or the like. In an embodiment, the firmness of theinterconnected fabric encased foam springs 108 may be configured in thebed facility to meet the comfort requirements of the user.

In an embodiment, there may be a machine to encase the foam into thefabric cylinder. In an embodiment, the foam springs 108 and fabric orfabric cylinders may be loaded into the machine. The machine may take anindividual foam spring 108 and wrapped it with the fabric or the fabriccylinder. In an embodiment, the machine may use fabric and shape thefabric into the cylinder shape as part of the assembly process. In anembodiment, once the foam spring 108 is wrapped within the fabriccylinder, the machine may stage the completed fabric wrapped foamsprings 108 for connecting into interconnected fabric encased foamsprings 108. In an embodiment, the machine may be capable of connectingthe individual fabric encased foam springs 108 into any orientation toassemble the interconnected fabric encased foam springs 108 that mayinclude a line of foam springs, a circle of foam springs 108, a squareof foam springs 108, a rectangle of foam springs 108, or the like.

In an embodiment, the foam spring 108 attachment facility 120 may beused to provide connection to adjacent foam springs 108, connection tothe containment facility 104, or the like to assure the maintainingplurality of foam springs 108 orientation within the mattress outercase. As previously discussed, the plurality of foam springs 108 mayhave certain orientations that may provide various foam spring 108firmnesses to provide relief for user discomfort. In an embodiment, amethod and system of foam spring 108 containment may be used to assurethat the preferred orientation of the plurality of foam springs 108 doesnot change, move, realign, or the like over time and use of the bedfacility 102. In an embodiment, the foam springs 108 may directlyconnect together using mechanical attachment, direct attachment, or thelike. In an embodiment, the containment facility 104 may be used toconnect to the foam springs 104 using the geometric shape, themechanical attachment device, the direct attachment device, or the like.

In an embodiment, the containment facility may be a patterned holdingdevice that may provide positioning for the foam springs 108 within themattress outer case. The pattern may provide the orientation of the foamsprings 108 within the mattress outer case and therefore may provide thelocations where various firmness foam spring 108 may be located. In anembodiment, the foam springs 108 may be placed only in the containmentfacility 104, placed without the containment facility 104, placed as acombination of in the containment facility 104 and without thecontainment facility 104, or the like. In an embodiment, the foamsprings 108 that may be placed without the containment facility 104 maydirectly connect to adjacent foam springs 108, may not directly connectto adjacent foam springs 108, or the like. In an embodiment, thecontainment facility 104 may have the same shape as the mattress outercase, mattress, bed facility 102, or the like.

In an embodiment, the containment facility 104 may contain a presetpattern, an adjustable pattern, a plurality of patterns, or the like. Inan embodiment, more than one containment facility 104 may be used withina mattress outer case. The individual containment facilities 104 maycontain different patterns, may have different sized openings fordifferent sized foam springs 108, or the like. In an embodiment, morethan one containment facility 104 may be connected together to form alarger containment facility. For example, a first containment facility104 may have a square pattern for the foam springs 108 and a secondcontainment facility 104 may have a hexagon pattern for the foam springs108. The square patterned containment facility 104 may be useful for auser's back area while the hexagon patterned containment facility 104may be useful in a user's shoulders and hips. In an embodiment, the morethan one containment facilities 104 may be connected together to form alarger containment facility 104, may be independent from each other, maybe a combination of connected and independent containment facilities104, or the like. In an embodiment, the more than one containmentfacility 104 may be combined to provide localized support to meet auser's requirement for discomfort relief. For example, within a mattressouter case, square containment facilities 104 may be used at a usershead, back, and leg locations while the hexagon containment facilitiesmay be used for the user's shoulders and hips. This configurationcapability may provide for improved targeting of certain firmness foamsprings 108 to a users requirement.

In an embodiment, the containment facility 104 may be made frommaterials, non-rigid materials, a combination of rigid and non-rigidmaterials, and the like. In an embodiment, a rigid containment facility104 may be made of metal, plastic, or the like. In an embodiment, aflexible containment facility 104 may be a cable, a rope, a strap, aweb, an elastic material, foam, or the like. In an embodiment, thecontainment facility 104 may include both rigid and non-rigid materials.For example, the containment facility 104 may be rigid but may containnon-rigid materials to connect to the foam springs 108. One example of apossible embodiment of the present invention is shown in FIGS. 4 a and 4b. The density of the latex foam is varied in different cylinder-shapedcomponents that may be referred to as “barrel coils.” The barrel coilsmay vary in density and therefore in their ILD (softness/firmnessrating) because the density of latex foam has a direct correlation withILD. Individually molded latex barrels/cylinders are connected to eachother by a fabric webbing. Such fabric webbing is then pulled throughthe foam encasement on the sides of the mattress to hold the barrels inplace. This is only one possible embodiment of the present invention,and it should be understood that many different configurations andmaterials may be used.

In another embodiment of the containment facility 104 may be a layer offoam with a pattern of holes for placing the foam springs 108; the layerof foam may have substantially the same shape as the bed facility 102.The foam springs 108 may be attached to the layer of foam using Velcro,tape, double stick tape, glue, elastic, matching geometric patters inthe layer of foam and foam spring 108, or the like. In an embodiment,there may be more than one layer of foam used to contain the foamsprings 108. In an embodiment, the layer of foam may connect to the foamsprings 108 in predetermined locations on the foam springs 108. Forexample, a single layer of foam may contact the foam springs 108 at thecenter of the foam springs 108. In another example, if two layers offoam are used, the contact may be at the top and bottom of the foamspring 108.

In another embodiment, the containment facility 104 may be a side foamrail 1112, a foam bottom layer, a foam top layer, or the like thatinclude indentations in which the foam spring 108 may fit. As an exampleshown in FIG. 11E, the side foam rails 1112 may have an indentationshape 1114 to hold the same shaped foam spring and the foam springs 108may fit into the side rail indentations 1114 to hold the foam springs108 in the correct orientation. FIG. 11E more particularly shows anembodiment of an indentation shape 1114 to hold the foam spring 108having a shape depicted in FIG. 2. Separately from or in combinationwith the indented side rails 1112, the top foam layer and/or the bottomfoam layer may have indentations in the shape of the foam spring ends tohold the foam springs in the correct orientation. In an embodiment, theindentations in the top and/or bottom foam layers may provide a nestinglocation for the foam spring to provide orientation positioning.

In another embodiment, the containment facility 104 may hold acombination of foam springs 108 and metal inner springs. In anembodiment, the metal inner springs may be used side by side with thefoam springs, the metal inner springs may be under the foam springs 108,the metal inner springs may be above the foam springs 108 or the like.The metal inner springs may be used to provide added support to theuser, localized support to the user, or the like.

In an embodiment, it may not be required that each patterned containmentfacility opening have a foam spring 108.

In an embodiment, the containment facility 104 may have pattern openingsthat provide locations for the various foam springs 108 firmnesspatterns that may be required by the user. In an embodiment, the foamspring 108 firmness pattern may be determined using certain containmentfacilities 104. For example, before proceeding with the determination ofthe foam spring 108 requirements, the type of containment facility 104may be determined that may provide the patterned opens to support thefoam spring 108 firmness patterns. In considering the users comfortneeds, a certain containment facility 104 may be selected that mayprovide for the proper targeting of foam springs 108 in the arearequired. For example, a user may select a containment facility 104 thehas a pattern that provides proper general support to his or her backbut may also have foam spring 108 openings that may be used to target aparticular firmness to the users shoulders.

A person knowledgeable in the art may understand that the containmentfacility 104 and foam spring 108 combinations may take many differentconfigurations to provide the user comfort required.

In an embodiment, using the containment facility 104, the foam spring108 pattern may be installed into the mattress outer case by a bedfacility 102 manufacturer, by a bed facility 102 enterprise, by a bedfacility 102 setup enterprise, by a user, or the like. In an embodiment,after the initial foam spring 108 pattern is set, the foam spring 108pattern may be altered by the bed facility 102 manufacturer, the bedfacility 102 enterprise, the bed facility 102 setup enterprise, theuser, or the like. In an embodiment, the altering of the foam spring 108pattern may be a result of changing user comfort conditions, changinguser requirements, or the like.

In an embodiment, the user may contact a bed facility 102 enterprise forthe determination of the foam spring 108 pattern that may provide theuser with his or her desired bed facility 102 comfort. In an embodiment,the foam spring 108 pattern may include foam spring 108 firmness, foamspring 108 firmness location, or the like. In an embodiment, the foamspring 108 pattern may be determined by an iterative trial, an interviewof the user by the bed facility 102 enterprise, by questionnaire, bysoftware application determination, or the like.

In an embodiment, the iterative trial may be the trial and error methodof physically trying a first foam spring 108 pattern with the usertrying the foam spring 108 pattern configuration and, based on the usersinput, making changes to the first pattern to create a second pattern.

In an embodiment, the interview process may involve the user and the bedfacility 102 enterprise discussing the needs of the user to determinehow the foam spring pattern may be configured to best fit the user. Inan embodiment, the bed facility 102 enterprise may use the informationfrom the interview to establish a foam spring 108 pattern based onprevious patterns, a set of patterns, experience, or the like. In anembodiment, after the initial pattern is determined, a trial process maybe used to find the final foam spring 108 pattern.

In an embodiment, the user may fill out a questionnaire that may requestinformation on the comfort requirements the user may require. Using theanswers to the questionnaire the bed facility 102 enterprise maydetermine the foam spring 108 pattern. In an embodiment, thequestionnaire answers may provide a guided method and system to the foamspring 108 pattern determination, may provide at least one complete foamspring 108 pattern, may provide a first foam spring 108 pattern fortrial, or the like.

In an embodiment, the software application may be a questionnaire thatmay request information on the comfort requirements the user mayrequire. Using the answers to the questionnaire, the softwareapplication may determine the foam spring 108 pattern. In an embodiment,the questionnaire answers may provide a guided method and system to thefoam spring 108 pattern determination, may provide at least one completefoam spring 108 pattern, may provide a first foam spring 108 pattern fortrial, or the like. The software application will be discussed in moredetail below.

In an embodiment, once the foam spring 108 pattern is determined, thefinal foam spring 108 pattern may be place into the containment facility104 and bed facility 102 for the user. The final foam spring 108 patternmay be created by the manufacturer, the bed facility 102 enterprise, thebed facility 102 setup organization, the user, or the like.

In an embodiment, the bed facility 102 manufacturer may have aninventory of various foam springs 108 to select from to build the userfoam spring 108 pattern. In an embodiment, the bed facility 102manufacturer may use the foam spring 108 pattern information receivedfrom the user/bed facility 102 enterprise to build the foam spring 108pattern to the users requirements. After the bed facility 102 iscomplete, including the foam spring 108 pattern, the bed facility 102may be transported to the bed facility 102 enterprise, the bed facility102 setup enterprise, the user, or the like.

In an embodiment, the bed facility 102 enterprise may have an inventoryof various foam springs 108 to select from to build the user foam spring108 pattern. In an embodiment, the bed facility 102 enterprise may usethe foam spring 108 pattern information determined with the user tobuild the foam spring 108 pattern to the users requirements. In anembodiment, the bed facility 102 enterprise may select foam springs 108from inventory to build the bed facility 102 that includes the userdetermined foam spring 108 pattern.

In an embodiment, the bed facility 102 setup enterprise may have aninventory of various foam springs 108 to select from to build the userfoam spring 108 pattern. In an embodiment, the bed facility 102 setupenterprise may use the foam spring 108 pattern information determined bythe user/foam spring 108 enterprise to build the foam spring 108 patternto the users requirements. In an embodiment, the bed facility 102 setupenterprise may select foam springs 108 from its inventory to build thebed facility 102 at the user's location; the bed facility 102 includesthe user determined foam spring 108 pattern.

In an embodiment, the user may purchase at least one set of foam springs108 that match the foam spring 108 pattern developed with the bedfacility 102 enterprise. In an embodiment, at the user's location, theuser may assemble the bed facility 102 with the predetermined foamspring 108 pattern.

As previously discussed, over time the users comfort requirements maychange and the change may require the firmness of the foam springs 108,the foam spring 108 pattern, or the like to be changed to match theuser's needs. In an embodiment, once the bed facility 102 with the userrequired foam spring 108 pattern has been initially assembled, theconfiguration may altered by the bed facility 102 manufacturer, the bedfacility 102 enterprise, the bed facility 102 setup enterprise, theuser, or the like. In an embodiment, the bed facility reconfigurationmay be enabled at a retail store, at a home of a user, or the like. Inan embodiment, the bed facility may be provided with a zipper or otherattachment device to allow access to the foam springs 108. The foamsprings 108 may be contained in a webbing that allows hand removal andreplacement of the foam springs 108. In an embodiment, the bed facilityreconfiguration may be enabled at a retail store, at a home of a user,or the like. In an embodiment, the bed facility may be provided with azipper or other attachment device to allow access to the foam springs108. The foam springs 108 may be contained in a webbing that allows handremoval and replacement of the foam springs 108. Using methodspreviously discussed, the foam spring 108 pattern, foam spring 108firmness, or the like may be revised by trial process, questionnaire,interview, software application, or the like. In an embodiment, once anew foam spring 108 pattern has been determined, the existing foamsprings 108 may be removed from the mattress outer case and the newlydetermined foam spring 108 pattern may be assembled into the mattressouter case. In an embodiment, the foam spring 108 pattern may be alteredas often as required by the user.

In an embodiment, the bed facility 102 enterprise, bed facility 102setup enterprise, the bed facility 102 manufacturer, or the like mayoffer predetermined foam spring 108 patterned bed facilities 102. Theremay be a number of standard foam spring 108 pattern bed facilities 102that may be historically preferred, provide standard relief forparticular user discomfort, or the like. In an embodiment, the standardbed facility 102 may have a certain number of areas or zones that havefoam spring 108 firmnesses that may provide comfort to users with commoncomfort requirements. For example, a predetermined foam spring 108pattern may be a medium firmness foam spring 108 under thehead/shoulders, a firmer foam spring 108 under the back, and a less firmfoam spring 108 under the legs. In another example, there may bepredetermined foam spring 108 patterns for hip, shoulder, neck, leg, orthe like comfort. In an embodiment, a user may purchase a standard bedfacility 102 with a predetermined foam spring 108 pattern that may meetthe user's requirements and may make firmness adjustments to the foamspring 108 pattern with purchased replacement foam springs 108.

In an embodiment, the bed facility 102 may have a uniform (orsubstantially uniform) firmness by using foam springs 108 of all (orsubstantially all) the same firmness.

A foam spring orientation application software 118 may be used todetermine the placement of the plurality of foam springs 108 within themattress outer case. In an embodiment, the foam spring orientationapplication software 118 may be a stand-alone application, a serverapplication, a web application, or the like. In an embodiment, theplurality of foam springs 108 may be of differing firmnesses and thefoam spring orientation application software 118 may be used todetermine the proper placement of the different foam spring 108firmnesses to meet the users comfort requirements. For example, the usermay require certain locations of the mattress to be less firm, morefirm, or the like to help provide the proper support for a part of hisor her body that may be experiencing discomfort such as a hip, shoulder,back, neck, knee, or the like. The user may have had an accident,surgery, suffer from arthritis, or the like and different firmnesseswithin the bed facility 102 may be required to provide the propercomfort for these areas of discomfort.

In an embodiment, the foam spring orientation application software 118may present questions to a user to determine the comfort requirements ofthe user's bed facility 102. The questions may be presented to the useras a paper questionnaire, a computer questionnaire, indicating on achart of the body the areas needing comfort consideration, or the like.In an embodiment, the user may interact with the foam spring orientationapplication 118 at the user's location, at the bed facility 102enterprise, at the bed facility 102 setup enterprise, at the bedfacility 102 manufacturer, or the like.

In an embodiment, the questionnaire may contain preset questions thatmay be input to a computer device from a completed paper questionnaire,interactively on the computer device, or the like. In an embodiment, thecomputer device may be a desktop computer, a laptop computer, a tabletcomputer, a kiosk, a PDA, a smart phone, or the like. In an embodiment,the computer device may work with a network that may be a LAN, WAN,Internet, intranet, wireless, wired, or the like. In an embodiment, thecomputer device interactive questionnaire may present additionalquestions to the user based on the answer to a previous question. Forexample, a first question may ask if the user suffers from discomfort inhis or her back. If, for example, the user answers yes, thequestionnaire may continue to ask questions that are particular to backdiscomfort such as location of pain, pain levels, if the pain is sharp,if the pain is dull, if the pain increases with time, and the like.

In an embodiment, the user may indicate on a body chart the areas ofdiscomfort that may require various foam spring 108 firmnesses. In anembodiment, the body chart may be in paper form, on a computer device,or the like. In an embodiment, the body chart operated on a computerdevice may incorporate a touch screen to enable the user to touch thelocations on the computer screen that may require addition comfortcontrol. In an embodiment, the user may indicate the location, the typeof discomfort, the intensity of discomfort, and the like that the formspring orientation application software 118 may be able to interpretinto bed facility 102 firmness requirements. In an embodiment, the bodychart may be divided into a grid, sections, zones, or the like to allowthe user to define the location of discomfort.

In an embodiment, after the questionnaire is complete, the applicationsoftware 118 may determine at least one configuration of foam springs108 for the bed facility 102. The configuration my include foam springs108 of varying firmness to provide a firmness configuration that maymatch the firmness requirements of the user. For example, if the userindicated in the questionnaire that he or she suffered from back pain inthe lower back area, the foam spring orientation application software118 may configure less firm or firmer foam springs in the area of thelower back. The remainder of the bed facility 102 may be configured tohave a standard firmness to properly support the remainder of the user'sbody. This configuration of varying firmness across the bed facility 102may provide the user with a comfortable position to rest, sleep, or thelike.

In an embodiment, after the foam spring orientation application software118 has determined the foam spring 108 configuration for the user, atest configuration may be setup in the bed facility 102 enterprise forthe user to try the form spring 108 configuration. Based on the usertrying the foam spring 108 configuration at the bed facility 102enterprise, the foam spring 108 configuration may be modified to improvethe bed facility 102 comfort.

In an embodiment, the foam spring 108 configuration may be manuallymodified by the user or the bed facility enterprise by interchangingform springs 108 and retrying the comfort of the bed facility 102 untila desired comfort has been reached. In another embodiment, the answersto the foam spring orientation application software 118 may be revisedand the foam spring orientation application software 118 may provide anew foam spring 108 configuration for the user to try. In anotherembodiment, the foam spring orientation application software 118 mayhave provided more than one foam spring 108 configurations and the usermay try at least one of the additional configurations to determine ifone of the additional configurations provides the desired comfort.

In an embodiment, the foam spring orientation application software 118may be a web application; the web application may store the final foamspring 108 pattern configuration. In an embodiment, if the foam spring108 pattern requires modification, the bed facility 102 enterprise, bedfacility 102 manufacturer, bed facility 102 setup enterprise, user, orthe like may use the stored foam spring 108 pattern information torevise the foam spring 108 pattern using the web accessed foam springorientation application software 118. In an embodiment, the web-basedapplication may have the same questionnaire that was used to determinethe original foam spring 108 pattern. In an embodiment, the web-basedfoam spring orientation application software 118 may be accessed, withthe user's stored information, and the information revised to match themost recent user information. In an embodiment, the web-based foamspring orientation application software may determine at least onerevised foam spring 108 pattern.

In an embodiment, after the revised foam spring 108 pattern isdetermined, the new foam springs 108 that may be required by the revisedfoam spring 108 pattern may be order by the web-based foam springorientation application software. In an embodiment, the revised foamspring 108 pattern may be assembled by the bed facility 102manufacturer, the bed facility 102 enterprise, the bed facility 102setup enterprise, user, or the like.

In another embodiment, the user may use the foam spring orientationapplication software 118 to reconfigure the foam spring 108configuration. In an embodiment, the user may have been provided a copyof the foam spring orientation application software 118 that the usermay operation on the users own computer device. The user may inputrevised answers to the questionnaire; the new questionnaire answers maybe used to determine a new foam spring 108 configuration.

A bed facility 102 may be any type of bed that provides a comfortableposition to a user for resting, sleeping, sitting, convalescing, or thelike. The bed facility 102 may be a standard non-adjustable bed, anadjustable bed, and the like. In an embodiment, the bed facility 102 mayinclude a mattress, box spring, support frame, and the like. In anembodiment, the mattress may include a material top layer (e.g. foam ormaterial), springs, foam layers, and the like. The bed facility 102 maybe used as a supportive facility for resting and sleeping by users ofany age and may include infant beds (e.g. cribs), children beds, bunkbeds, adult beds, and the like. In an embodiment, beds may be made ofvarious different sizes such as twin, full, queen, king, and the likefor different situations and user requirements. The bed sizes may beindustry standard sizes but there may also be more than one standardsize for a bed type such as a long twin bed verses a standard sized twinbed.

A standard non-adjustable bed may be any bed that maintains a singlerigid position that may not be capable of changing shape or position. Inan embodiment, the standard non-adjustable bed may typically be used ina bedroom for sleeping, resting, or the like and may provide a flathorizontal surface for the user to lie down on. Additionally, thenon-adjustable bed may be a single rigid shape that may have a non-flatconfiguration. Typically, the standard non-adjustable bed may berectangular in shape, but may also be in other shapes such as round,square, or the like.

An adjustable bed may be a type of bed that capable of adjusting atleast one aspect of the bed shape such as a head section, a footsection, leg section, a torso section, or the like. In an embodiment,there may be a control interface that a user may use to adjust theposition of at least one aspect of the bed. In an embodiment, the bedposition adjustment may be to provide a more comfortable position to theuser for performing a task (e.g. writing at a work station), relief frompain, watching TV, provide a different sleeping position, improved bloodcirculation (e.g. elevated head or feet), and the like. In anembodiment, the bed structure may be flexible, hinged, or the like toprovide locations for the adjustable bed to move into differentpositions.

In an embodiment, the bed facility 102 may use a mattress that containsfoam springs 108 to support the user. In an embodiment, the foam spring108 may be made of any type of soft foam that may include latex foam,urethane foam, visco-elastic foam, polyurethane foam, or the like. In anembodiment, the foam spring 108 may be contained in a mattress outercasing; the mattress outer casing may be in the shape of the bed. In anembodiment, the foam spring 108 may provide direct support to the user,provide indirect support by supporting an over layer of material, or thelike. In an embodiment, the foam spring 108 may typically be of a heightto fit between the top and bottom surfaces of the mattress outer casing.In another embodiment, the foam spring 108 may be a portion of theheight of the mattress outer casing and more than one foam spring may beplaced on top of another to fill the space between the top and bottom ofthe mattress outer casing.

In an embodiment, the foam spring 108 may have a cross sectional shapethat may include round, square, hexagon, octagon, star shaped, oval, orthe like. In an embodiment, foam springs 108 may be used in any facilitythat a user may require soft supportive characteristics such as beds,pillows, chairs, couches, and the like. In an embodiment, there may be aplurality of foam springs 108 used in a mattress outer casing to providesupport to a user. The plurality of foam springs that may be used withinthe volume of the mattress outer casing may be a combination of crosssectional shapes. For example, the mattress outer casing volume may usea combination round and oval shaped foam springs 108 to provide adifferent foam spring 108 configuration to different parts of themattress. In an embodiment, the plurality of foam springs 108 may fittogether such that there may be spaces between the foam springs 108; thespaces may provide freedom of motion for the plurality of foam springs.In another embodiment, the shape of the foam springs 108 may be selectedthat provides for the foam springs 108 to fit tightly together; thetight fit may allow each foam spring 108 to provide support to adjacentfoam springs 108. In an embodiment, the cross sectional shape of thefoam springs 108 selected for placement within a mattress outer casingmay provide for differing support characteristics to the user. Forexample, looser fitting foam springs 108 may provide for a softersupport structure to the user while the tighter fitting foam springs 108may provide a firmer support structure.

In an embodiment, the foam spring 108 may be solid foam, may containinterior openings, may contain exterior openings, may contain acombination of interior and exterior openings, or the like. In anembodiment, the foam spring 108 interior and exterior openings may notinfluence the spring foam 108 firmness but may be used formanufacturability, to provide space to allow movement of the foam spring108, or the like. For example, an interior opening of the foam spring108 may be used during manufacturing to provide for mold shapes, allowadditional area for air injection, or the like. In an embodiment, theinterior and exterior openings may be used to provide holding area forhealth benefit materials such as activated carbon, tourmaline, magnets,and the like.

In an embodiment, the foam springs 108 may have differing firmness thatmay be defined by an indentation load deflection (ILD) value,indentation force deflection (IFD) value, foam density, or the like.IFD, and in a similar manner ILD, is defined as the amount of force, inpounds, required to indent a fifty square inch, round surface into afoam material a certain percentage of the foam material total thickness.IFD may be specified as the number of pounds at a specific deflectionpercentage for specific height foam. For example, the IFD for a foam maybe defined as 25 pounds/50 in² at a 25% deflection on a four inch thickpiece. In an embodiment, the IFD may be influenced by the thickness ofthe foam material, the size of the material, and the like.

The firmness may also be measured or described by the density of thefoam, in pounds per cubic foot, kilograms per cubic meter, or some otherrelevant standard. Although the density may not be a direct measurementof firmness, it may have a direct relationship to firmness. For example,a 110 kg/m3 density barrel may be firmer than a 95 kg/m3 barrel and the95 kg/m3 barrel may be firmer than an 80 kg/m3 density barrel, and thelike.

In an embodiment, the different IFD foam density, or the like, andtherefore foam spring 108 firmness, may be varied or adjusted by usingdifferent density foam, different types of foam, or the like. In anembodiment, the foam spring 108 density may be varied by using differentpercentages of air when manufacturing the foam spring 108; the amountair used during the foam manufacture may provide the amount or size ofcells within the foam spring 108. For example, a foam spring 108 withmore air, and therefore more foam cells, may provide for lower densityfoam and therefore may be less firm.

In an embodiment, the foam spring 108 may include an attachment facility120 to allow more than one foam spring 108 to be associated with otherfoam springs 108 within a mattress outer casing; the attachment may beused to maintain the orientation of one foam spring 108 to another foamspring 108, the alignment of various firmness foam springs 108, or thelike. In an embodiment, the attachment facility 120 may be a feature onthe outer surface of the foam spring 108 such as a geometric shapedraised foam area, geometric shaped recessed foam area, attached Velcromaterial, mechanical snaps, clips, buckles, glue, adhesive, tape, or thelike.

A containment facility 104 may be a mechanical device that may be usedto contain, orient, and maintain the plurality of foam springs 108 in apattern within the volume of the mattress outer casing. In anembodiment, the containment facility 104 may be a rigid device,semi-rigid device, flexible device, or the like that may be preset, setby the user, preset and adjusted by the user, or the like. In anembodiment, a rigid containment facility 104 may be made of metal,plastic, or the like. In an embodiment, a flexible containment facility104 may be a cable, a rope, a strap, a web, or the like. In anembodiment, the rigid and flexible containment facilities 104 may becombined by having a rigid structure such as a plastic patternedcontainment facility 104 combined with a flexible component such as astrap to attach to the foam spring 108.

In an embodiment, the containment facility 104 may attach to each foamspring 108 attachment facility 120 and may be used to grip the foamspring 108 attachment facility 120, fit into the foam spring 108attachment facility 120, fit around the foam spring 108 attachmentfacility 120, connect to the foam spring 108 attachment facility 120, orthe like.

In an embodiment, the containment facility 104 pattern may be preset,user set, fixed, adjustable, a combination of preset and adjustable, orthe like. For example, the containment facility 104 may be delivered tothe user with a preset pattern but the user may be able to adjust thecontainment facility 104 pattern to position the foam springs 108 in auser desired pattern.

Activated carbon 110 is a material that has an exceptionally highsurface area that includes a large amount of micro porosity. Sufficientactivation for useful applications may come from the high surface areabut further chemical treatment may used to enhance the absorbingproperties of the activated carbon. Activated carbon attracts and holdscertain chemicals therefore reducing dust, odors, contaminates, and thelike from the area around the activated carbon. The contaminants may beattracted to and held (adsorbed) on the surface of the carbon particles.The characteristics of the carbon material (e.g. particle size, poresize, surface area, surface chemistry, density, and hardness) influencethe efficiency of adsorption.

In an embodiment, the activated carbon 110 may be mixed with the foamspring 108 material for the removal of contaminants from the bedfacility 102 environment. In another embodiment, the activated carbon110 may be added to the foam spring 108 as a separate filtering device.For example, the foam spring 108 may have an opening where activatedcarbon 110 may be added to act as a filter to remove contaminates fromthe air within and around the bed facility 102. The foam springmanufacturer, bed facility 102 enterprise, user, or the like may add theactivated carbon 110 to the foam spring 108. In this embodiment, theactivated carbon 110 may be replaceable.

In an embodiment, the activated carbon may be a coating on the foamspring, may be inserted into the annulus of the foam spring, may be aring around the perimeter of the foam spring, or the like.

Tourmaline 112 is a natural material that is a source of negative ionsand far infrared rays. Tourmaline 112 is believed to be useful forimproved circulation, relieving stress, improved mental alertness, andstrengthening immune system function.

In an embodiment, the tourmaline 112 may be mixed with the foam spring108 material during the foam spring 108 manufacture. In anotherembodiment, the tourmaline 112 may be added to the foam spring 108 as aseparate device. For example, the foam spring 108 may have an openingwhere tourmaline 112 may be added to add the health benefits oftourmaline to the bed facility 102. The foam spring manufacturer, bedfacility 102 enterprise, user, or the like may add the tourmaline 112 tothe foam spring 108. In this embodiment, the tourmaline 112 may bereplaceable.

In an embodiment, the tourmaline may be a coating on the foam spring,may be inserted into the annulus of the foam spring, may be a ringaround the perimeter of the foam spring, or the like.

Magnets 114 are believed to be useful for increased circulation, reducedinflammation, increased recovery speed from injuries, and the like. Inan embodiment, the magnets 114 may be mixed with the foam spring 108material during the foam spring 108 manufacture, placed in specificlocations in the foam spring 108 during manufacture, or the like. Inanother embodiment, the magnets 112 may be added to the foam spring 108as a separate device. For example, the foam spring 108 may have anopening where magnets 112 may be added to add the health benefits ofmagnets 112 to the bed facility 102. The foam spring manufacturer, bedfacility 102 enterprise, user, or the like may add the magnets 112 tothe foam spring 108. In this embodiment, the magnets 114 may bereplaceable.

In an embodiment, the magnets may be a coating on the foam spring, maybe inserted into the annulus of the foam spring, may be a ring aroundthe perimeter of the foam spring, or the like.

In an embodiment, the pattern of magnet placement within the foam spring108 and within the bed facility 102 may be important to the magnethealth benefits. In an embodiment, a magnet orientation application maybe used to determine the placement of the magnets within the foam spring108, bed facility 102, and the like. In an embodiment, the magnets maybe placed to provide an increased magnet influence to provide healthbenefits in certain locations. In an embodiment, the magnet orientationapplication may determine the location of magnets within each individualfoam spring 108.

A foam spring orientation application software 118 may be used todetermine the placement of the plurality of foam springs 108 within themattress outer case volume. In an embodiment, the plurality of foamsprings 108 may be of differing firmnesses and the foam springorientation application software 118 may be used to determine the properplacement of the different foam spring 108 firmnesses to meet the userscomfort requirements. For example, the user may require certainlocations of the mattress to be less firm, more firm, or the like tohelp provide the proper support for a part of his or her body that maybe experiencing discomfort such as a hip, shoulder, back, neck, knee, orthe like. The user may have had an accident, surgery, suffer fromarthritis, have a neck condition, have a knee condition, have a sleepdisorder, a disease or the like and different firmnesses within the bedfacility 102 may be required to provide the proper comfort for theseareas of discomfort.

In an embodiment, the foam spring orientation application software 118may present questions to a user to determine the comfort requirements ofthe user's bed facility 102. The questions may be presented to the useras a paper questionnaire, a computer questionnaire, indicating on achart of the body the areas needing comfort consideration, or the like.

In an embodiment, the questionnaire may contain preset questions thatmay be input to a computer device from a completed paper questionnaire,interactively on the computer device, or the like. In an embodiment, thecomputer device interactive questionnaire may present additionalquestions to the user based on the answer to a previous question. Forexample, a first question may ask if the user suffers from discomfort inhis or her back. If, for example, the user answers yes, thequestionnaire may continue to ask questions that are particular to backdiscomfort such as location of pain, pain levels, if the pain is sharp,if the pain is dull, if the pain increases with time, and the like.

In an embodiment, the user may indicate on a body chart the areas ofdiscomfort that may require various foam spring 108 firmnesses. In anembodiment, the user may indicate the location, the type of discomfort,the intensity of discomfort, and the like that the form springorientation application software 118 may be able to interpret into bedfacility 102 firmness requirements. In an embodiment, the body chart maybe divided into a grid, sections, zones, or the like to allow the userto define the location of discomfort.

In an embodiment, after the questionnaire is complete, the applicationsoftware 118 may determine at least one configuration of foam springs108 for the bed facility 102. The configuration my include foam springs108 of varying firmness to provide a firmness configuration that maymatch the firmness requirements of the user. For example, if the userindicated in the questionnaire that he or she suffered from back pain inthe lower back area, the foam spring orientation application software118 may configure less firm or firmer foam springs in the area of thelower back. The remainder of the bed facility 102 may be configured tohave a standard firmness to properly support the remainder of the user'sbody. This configuration of varying firmness across the bed facility 102may provide the user with a comfortable position to rest, sleep, or thelike.

In an embodiment, after the foam spring orientation application software118 has determined the foam spring 108 configuration for the user, atest configuration may be setup in the bed facility 102 enterprise forthe user to try the form spring 108 configuration. Based on the usertrying the foam spring 108 configuration at the bed facility 102enterprise, the foam spring 108 configuration may be modified to improvethe bed facility 102 comfort.

In an embodiment, the foam spring 108 configuration may be manuallymodified by the user or the bed facility enterprise by interchangingform springs 108 and retrying the comfort of the bed facility 102 untila desired comfort has been reached. In another embodiment, the answersto the foam spring orientation application software 118 may be revisedand the foam spring orientation application software 118 may provide anew foam spring 108 configuration for the user to try. In anotherembodiment, the foam spring orientation application software 118 mayhave provided more than one foam spring 108 configurations and the usermay try at least one of the additional configurations to determine ifone of the additional configurations provides the desired comfort.

In an embodiment, the bed facility 102 foam spring 108 configuration maybe iterated at the bed facility 102 enterprise until a foam spring 108configuration is determined that provides the desired comfort. In anembodiment, once the final foam spring configuration has beendetermined, the order for the bed facility 102 with the user's desiredfoam spring 108 configuration may be placed with a manufacturer fordelivery to the user, the configuration may be set in the bed facility102 enterprise and delivered to the user, or the like.

In an embodiment, after the user has received the bed facility 102 withthe user defined foam spring 108 configuration the user may be able toadjust the foam spring 108 configuration, change foam spring 108firmnesses, or the like. The user may adjust the configuration orfirmness of the bed facility 102 because of changing conditions (e.g.the discomfort improves or worsens), to provide a better comfortconfiguration, or the like. In an embodiment, the user may adjust thefoam spring 108 configuration manually by changing the location of thefoam springs 108, changing the firmness of the foam springs 108 incertain locations, or the like.

In another embodiment, the user may use the foam spring orientationapplication software 118 to reconfigure the foam spring 108configuration. In an embodiment, the user may have been provided a copyof the foam spring orientation application software 118 that the usermay operation on the users own computer device. The user may inputrevised answers to the questionnaire; the new questionnaire answers maybe used to determine a new foam spring 108 configuration.

In another embodiment, the user may use a web based foam springorientation application software 118 to revise answers to thequestionnaire to determine a new foam spring 108 configuration. In anembodiment, the user's previous answers to the questionnaire may bestored in the web based foam spring orientation application software 118and the user may be able to recall his or her answers and modify theanswers. Using the modified answers, the web based foam springorientation application software 118 may provide a new foam spring 108configuration to the user.

In an embodiment, similar to the iterative method of determining theuser's desired foam spring configuration at the bed facility 102enterprise, the user may iterate into a new foam spring 108configuration that matches the users comfort requirements.

Pending U.S. patent application Ser. No. 11/239,404 entitled“Combination Mattress” incorporated here by reference, describes amattress using individual foam springs. The patent application describesa combination mattress comprising a plurality of independent barrels offoam material. Each individual foam barrel may be combined together bythe outer diameter surfaces abutting and a user may adjust the positionof the barrels to change the firmness of the combination mattress.

The independent barrels are described as having two resting surfacesthat contact the upper and lower surfaces of the mattress, a centeropening, and a recess on the outer diameter surface. The recess on theouter diameter surface is used as a connection to a belt and a fixingmember to maintain the orientation of the independent barrels. Theindependent barrels may be placed in the fixing member to orient theindependent barrels into a firmness configuration to meet the user'srequirements. The user, as needed, may adjust the independent barrelorientation.

The independent barrels are described as having different shape inneropenings that provide for the varying firmness of the independentbarrels.

U.S. Pat. No. 6,704,962 entitled “Elastic Body, Method for Manufacturingthe Same and Mattress Including the Same” incorporated here byreference, describes an elastic body having a substantially cylindricalpillar-like shape having at least one concave portion at the centerthereof and at least two convex portions adjacent to the concaveportion; the convex portion has a spherical shape.

The elastic body is manufactured by mixing poly alcohol with polyetherin a ratio of 3-5 to 5-7 to prepare a polyether polyol compound. Methylalcohol is used as a solvent. A polyol mixture is obtained by mixing30-50 parts by weight of the obtained polyether polyol compound,2-2-parts by weight of polystyrene, a trace amount of a catalyst, andwater. A preferred viscosity of the obtained polyol mixture is about1100±300 cps at 40° C.

There may be two different types of elastic body, air permeable formsand non-air permeable forms. The firmness of a mattress is adjusted bythe ratio of air permeable and non-air permeable forms and the locationof the same within the mattress. A soft material supporter having holesat predetermined intervals hold the elastic bodies at the concaveportion.

The various previously described embodiments of the invention may befurther understood by reference to FIG. 2 through 32.

FIGS. 2A through 2C depict an embodiment of the foam spring 108. In oneembodiment, as shown in FIG. 2A, the foam spring 108 may be a solidresilient material that does not contain any additional features. Inanother embodiment, FIG. 2B depicts a foam spring with a center hole 202and an outer covering 208. As previously described, the center hole maybe used for different resilient material, activated carbon 110,tourmaline 112, magnets 114, and the like. The center opening 202 shownis round, but it should be understood that the opening 202 may shape. Inan embodiment, the outer covering 208 may be an encasing cloth that maybe used to contain the foam spring 108, may be used to connect to otherfoam springs 108, or the like. FIG. 2C shows an embodiment of the outercovering 212 only covering a portion of the foam spring 108. In thisembodiment, the outer coverings 212 may be combined together to formregions 122, zones, the entire bed facility 102, or the like and thefoam springs 108 may be inserted into the combined outer coverings 212.

FIG. 3 depicts an embodiment of a foam spring 108 that may includecenter openings 202, a combination of different resilient materials(304, 310), outer coverings 308, and the like. In embodiments, thepreviously described health benefit materials (e.g. activated carbon110, tourmaline 112, and magnets 114) may be placed within the openings202, may be part of the resilient material 304, may be a combination ofplaced within the opening 202 and mixed with the resilient material 304,or the like. As shown, the health benefit materials may be incorporatedinto only a portion of the resilient material 304 while the otherportion of resilient material 310 may not contain health benefitmaterials. It should be understood that the health benefit materials maybe in any combination within the foam spring 108.

As previously described, the foam spring 108 may have many differentshapes; these shapes may be used individually or in combination. FIGS.4A through 4E depict perspective views of various foam spring 108 shapesthat may be used. It should be understood that these shapes are examplesand is not intended to be a complete list of all the possible shapes forthe foam spring 108 and that there may be many additional shapes thatmay be used. Additionally, it should be understood that the differentfoam spring 108 shapes may be used individually or in combination withinthe bed facility 102.

FIG. 4F through FIG. 4M depict top views of various foal spring 108shapes that may be used. It should be understood that theses areexamples and is not intended to be a complete list of all the possibleshapes for the foam spring 108 and that there may be many additionalshapes that may be used. Additionally, it should be understood thatdifferent foam spring 108 shapes may be used individually or incombination within the bed facility 102.

As previously described, the foam spring 108 may have exterior andinterior openings. FIGS. 5A through 5D depict exterior and interioropenings and shapes that may be used on the foam spring 108 such ashorizontal ribs 502, vertical ribs 504, spiral ribs 508, and throughholes 510. It should be understood that these different exterior andinterior openings may be used individually or in combination on a singlefoam spring 108 or in a plurality of foam springs 108 within a bedfacility 102.

FIGS. 6A through 6C depict various configurations of foam spring 108within an attachment facility 120 webbing. As shown in FIG. 6A, the foamsprings 108 may be oriented with webbing 602 to provide spaces betweenthe foam springs 108. In FIG. 6B, the foam springs 108 are shownoriented with webbing 604 to provide a reduced amount of spacing betweenthe foam springs 108. FIG. 6C depicts a perspective view 608 of the foamspring 108 with reduced spaces and with the attachment facility 120webbing around the center of the foam spring 108. It should beunderstood that the attachment facility 120 may be any of the previouslydescribed attachment facilities 120 and the attachment facilities may beassociated to the foam springs 108 at any position (e.g. top, middle, orbottom).

FIGS. 7A and 7B depict the attachment facility 120 webbing attached tothe foam spring 108. In FIG. 7A, the attachment faculty 120 webbing isshown individually attached to the foam spring 108. As previouslydescribed, the individual foam springs may then be attached to formregions 122, zones, used within the entire bed facility 102, or thelike. FIG. 7B shows the foam springs 108 connected together in a region122. It should be understood that the foam springs 108 may be connectedwith individual attachments or may be connected with webbing.

FIG. 8 depicts a number of embodiments of attaching individual foamsprings 108 together. The depicted embodiments show the foam springs 108within individual outer covers 212, but it should be understood thatthese attachment embodiments may be used with full outer covers or withno outer covers.

In a first embodiment, clips 802 may be used to hold the individual foamsprings 108 together. In an embodiment, the clips may be in any shapethat is able to hold two foam springs 108 together. In a secondembodiment, snaps 804 may be used to hold the individual foam springs108 together. In a third embodiment, glue 808 is used to hold theindividual foam springs 108 together. In a forth embodiment, a hook andloop (e.g. Velcro) may be used to hold the individual foam springs 108together. It is shown that attachments are near the center of the foamspring 108, but it should be understood that the attachments may be onany location on the foam spring 108. Additionally, it should beunderstood that there may be more than one attachment for each foamspring 108. In an embodiment, the various attachments may be usedindividually or in combination.

FIG. 9 depicts one type of attachment facility 120 attaching a pluralityof foam springs 108. In embodiments, the attachment facility 120 mayattach any number of foam springs 108 in any type of configuration. Forexample, as shown, the foam springs may be contained into a rectangularshape, but the foam springs may also be configured into a square, round,hexagonal, octagonal, or any other shape. As previously described, theattachment facility 120 may be of a set shape, may be elastic, may befabric, may be a solid shape, or may be an other configuration to holdthe foam springs 108 within the containment facility 104.

FIG. 10 shows the contained foam springs 108 from FIG. 9 associated intoregions 122. As may be seen, the contained foam springs 108 may beoriented as organized regions 122 of foam springs 108.

FIGS. 11A through 11D depict different methods of orienting individualfoam springs 108 into positions in a foam panel 1102. It should beunderstood that the foam panel 1102 may be a top, bottom, or side foampanel within the containment facility.

As shown in FIG. 11A, a bottom foam panel 1102 may have openings 1104where the individual foam springs 108 may fit to provide orientation forthe foam spring 108 within the containment facility 104. In embodiments,the foam panel 1102 openings 1104 may be all the way through the foampanel 1102, partially through the foam panel 1102, or the like. In anembodiment, the openings 1104 may be in any pattern within the foampanel 1102.

In another embodiment, the foam panel 1102 may be a solid surfacedpanel, and the individual foam springs 108 may be attached to the foampanel 1102 or to each other using glue, hook and loop fastener, tape,double stick tape, epoxy, adhesive spray or the like. In an embodiment,the foam springs 108 may be attached to the foam panel 1102 in anypattern within the foam panel 1102.

As shown in FIG. 11B, a top foam panel 1102 may have openings 1104 wherethe individual foam springs 108 may fit to provide orientation for thefoam spring 108 within the containment facility 104. In embodiments, thefoam panel 1102 openings 1104 may be all the way through the foam panel1102, partially through the foam panel 1102, or the like. In anembodiment, the openings 1104 may be in any pattern within the foampanel 1102.

FIG. 11C depicts a foam spring 108 orientation embodiment where the foamsprings 108 have an internal opening that fits onto a foam panel 1102that includes vertical locators 1108. In this embodiment, the foamsprings 108 fit onto the vertical locators 1108 to be positioned withinthe containment facility. The foam spring 108 openings and the verticallocators are shown as round objects, but it should be understood thatthe openings and the vertical locators 1108 may be any shape.

FIG. 11D depicts a foam spring 108 orientation embodiment where the foamsprings 108 fit into shapes created by vertical and horizontal locators1110. In this embodiment, the horizontal and vertical locators 1110 areplaced onto the foam panel 1102 in a configuration to create a square orrectangular openings. In this case, the foam springs 108 are shown asrectangular shapes to fit into the configuration created by thehorizontal an vertical locators 1110. It should be understood that thelocators 1110 may be placed in any orientation to create openings tocontain the foam springs 108.

FIG. 12 depicts an embodiment of an overall foam spring 108 orientationwhere the foam springs 108 are oriented in a regular rectangularconfiguration within the containment facility 104. As previouslydescribed, the foam spring 108 orientation may be maintained using theattachment facility 120. This view is provided as an example of a foamspring 108 orientation within the containment facility 104, but aspreviously described, the foam spring 108 orientation may be in anyconfiguration within the containment facility 120.

FIG. 13 depicts an embodiment of a plurality of foam springs 108orientated into regions 122 within the containment facility 104. In thisembodiment there are three regions 122 that may be for the users head,body, and leg areas within the bed facility 102. In an embodiment, theregions 122 may be created by the foam springs 108 contained using oneof the attachment facilities 120. This embodiment depicts three regionswithin the containment facility 104, but it should be understood thatthere may be any number of regions 122. As previously described, each ofthese regions 122 may have different firmnesses to meet the usersfirmness requirements. For example, the head region 122 may be of amedium firmness while the body region 122 may be firmer.

FIG. 14 depicts an embodiment where different foam spring 108 firmnessmay be mixed within the regions 122. For example, the head region mayhave less firm foam springs 1402 to allow the users head to be supportedby the surrounding firmer foam springs 108 and the back region may havefirmer foam springs 1404 in the lower back area to provide firmersupport to the user's back. Additionally, there may be differentfirmness areas within a region 122. For example, it is shown that thereare two different firmnesses (1408 and 1410) in the leg region. Thedifferent firmness areas within a region may allow a user's comfortrequirements to be met in particular locations of the bed facility 102.It should be understood that the foam spring 108 firmness may bedistributed in any configuration within the containment facility 104 tomeet the user's firmness requirements.

FIG. 15 depicts an embodiment where the foam spring 108 firmnesses maybe mixed within an area of a region 122. For example, it is shown in thehead region that a first firmness 1502 surrounds a second firmness 1504foam spring 108. In another embodiment, the firmness of an area may becreated by mixing different foam spring 108 firmness together within aregion. In the body region 122, it is shown that the different firmness1508 foam springs 108 are alternated to provide an overall firmness forthis region 122. In a different alternating sequence, the foot region isshown with a first firmness 1510 directly alternating with a secondfirmness 1512. It should be understood that the mixing of the differentfirmnesses of foam springs 108 may be provided in any configuration tomeet the use's comfort requirements. For example, there may be adifferent configuration for each shoulder area to provide for thecomfort of each of the user's shoulders.

As previously described, magnets may be included with the foam springs108 to provide health benefits to the user. FIG. 16 shows an embodimentwhere foam springs with magnets 1602 are configured within thecontainment facility 104. It should be understood that the form springs108 containing magnets 1602 may be in any configuration within thecontainment facility 104.

As previously described, activated carbon may be included with the foamsprings 108 to provide health benefits to the user. FIG. 17 shows anembodiment where foam springs with activated carbon 1702 are configuredwithin the containment facility 104. In this case the activated carbonfoam springs 1702 may be placed by the users head to provide airfiltering. It should be understood that the form springs 108 containingactivated carbon 1702 may be in any configuration within the containmentfacility 104.

As previously described, tourmaline may be included with the foamsprings 108 to provide health benefits to the user. FIG. 18 shows anembodiment where foam springs with tourmaline 1802 are configured withinthe containment facility 104. In this case the tourmaline foam springs1802 may be placed by the users back to provide increased bloodcirculation. It should be understood that the form springs 108containing tourmaline 1802 may be in any configuration within thecontainment facility 104.

FIG. 19 depicts the use of hydraulic or pneumatic chambers 1904 to beused in conjunction with foam springs 108. In this embodiment, the foamspring orientation application facility 118 may be used to determine thefirmness requirements of the user. The firmness information may beprovided to a hydraulic or pneumatic facility 1902 that may provide theproper firmness to the chambers 1904. As previously described, thehydraulic or pneumatic chambers 1904 may be used individually or incombination with the foam springs 108.

FIG. 20 shows another embodiment of the hydraulic or pneumatic chambers1904 where there may be a region 122 or individual control of thechambers 1904. In this embodiment, the individual chambers or regions122 of chambers may have controlled firmnesses. As in FIG. 19, thehydraulic or pneumatic facility 1902 may provide the proper firmnesscontrol the individual chambers 1904 or the region 122 of chambers 1904.

FIGS. 21A through 21D depict embodiments of foam springs 108 beingcombined with metal springs 2102. As previously described, foam springs108 may be combined with metal springs 2102 to provide the user with thedesired firmness.

FIG. 21A shows a configuration of the foam spring 108 on top of themetal spring 2102.

FIG. 21B shows a configuration of the foam spring 108 below the metalspring 2102.

FIG. 21C shows a combination of foam springs 108 above and below themetal springs 2102. It should be understood that the combination of foamspring 108 and metal springs 2102 may be in any orientation within thecontainment facility 104.

FIG. 21D shows an embodiment of the foam springs 108 alternated with themetal springs 2102. It should be understood that the foam springs 108and metal springs 2102 may be in any configuration within thecontainment facility 104.

FIG. 22 shows an embodiment of accessing the foam springs 108 after thefoam springs 108 have been installed into the containment facility 104.As previously described, over time the user's comfort requirements maychange and the foam spring 108 configuration may need to be revised. Inthis embodiment, a zipper 2202 may be used to open up the containmentfacility 104 to provide access to the foam springs. It should beunderstood that there may be a number of devices that may be usedinstead of a zipper to gain access to the foam springs 108 such asVelcro, snaps, buttons, or the like.

FIG. 23 depicts another embodiment for accessing the foam springs 108within the bed facility 102. In this embodiment, sections or regions 122of the bed facility 102 may slide out the side of the bed facility 102to access the foam springs 108.

FIG. 24 shows an embodiment of a pillow 2402 and a neck pillow 2404using foam springs 108. As may be understood, different sizes andheights of foam springs 108 may used in the pillows (2402 and 2404)

FIG. 25 shows an embodiment of a chair cushion 2502 using foam springs108.

FIG. 26 shows an embodiment of an automobile seat using foam springs108. FIG. 26 shows a side view of an automobile seat 2502 and a top viewof the automobile seat 2504. As may be seen in the figure, there may bemany different foam springs 108 used in the automobile seat 2502 tomaintain the proper user positioning and comfort.

FIGS. 27 through 32 depicts various steps and methods of determining theconfiguration orientation for the foam springs 108 within thecontainment facility 104. While the embodiment described is for asoftware application, user information for the bed facility 102configuration may also be collected using a questionnaire.

FIG. 27 depicts an embodiment of the starting screen 2702 for the foamspring orienting software application 118. In this embodiment, there maybe a virtual image 2704 of a user superimposed on a bed facility 102containing a plurality of foam springs 108. In an embodiment, thestarting configuration of the foam springs 108 for the bed facility 102may not contain any special configuration of different foam spring 108firmnesses.

FIG. 28 depicts an embodiment of a foam spring orienting softwareapplication 118 screen requesting information from the user on the typeof bed facility 102 to be configured. In this embodiment, the user,possibly with the aid of an enterprise or manufacturer, may input thetype of bed facility 102 to be customized for the user's comfortrequirements.

FIG. 29 depicts an embodiment of a foam spring orienting softwareapplication 118 screen requesting information from the user on thepreferred firmness of bed facility 102 to be configured. In thisembodiment, the user may be asked to select the overall firmness of thebed facility or the user may be able to indicate the firmness of thevarious regions 122 of the bed facility 102.

FIG. 30 depicts an embodiment of a foam spring orienting softwareapplication 118 screen requesting user specific information that may beused to make specific calculations of the bed facility 102 configurationof bed facility 102. As previously described, after the user answers anyof the questions, additional questions may be presented to the user togather additional information. For example, depending on the answer theuser provides to “What parts of your body feel best when you wake?”,additional questions may be presented to the user to gather additionaldetail. It should be understood that many different types of informationmay be asked of the user, and this questions on FIG. 30 are presented asexamples only.

FIG. 31 depicts an embodiment of a feedback screen from the foam springorientation software application 118 where an inventory of the foamspring 108 type and firmness that may be required to meet the userscomfort requirements are shown. In this embodiment, the foam spring 108listing 3102 is presented with a matching indicator and a schematic 3104showing the placement of the foam springs 108 from the inventory listing3102 may be displayed.

FIG. 32 depicts an embodiment of an ending screen 2702 for the foamspring orienting software application 118 showing the finalconfiguration of foam springs 108 within the bed facility 102. In thisembodiment, the virtual user 2704 may be superimposed over the finalconfiguration of foam springs 108 that are configured for firmness tomeet the users comfort requirements. It should be understood that theseare example screens and the screens may present and request informationto the user in many different screen embodiments. Additionally, itshould also be understood that at any time during the informationgathering or presenting of information to the user, the applicationsoftware may be able to go back to previous screens or forward to nextscreens to review or change information.

The elements depicted in flow charts and block diagrams throughout thefigures imply logical boundaries between the elements. However,according to software or hardware engineering practices, the depictedelements and the functions thereof may be implemented as parts of amonolithic software structure, as standalone software modules, or asmodules that employ external routines, code, services, and so forth, orany combination of these, and all such implementations are within thescope of the present disclosure. Thus, while the foregoing drawings anddescription set forth functional aspects of the disclosed systems, noparticular arrangement of software for implementing these functionalaspects should be inferred from these descriptions unless explicitlystated or otherwise clear from the context.

Similarly, it will be appreciated that the various steps identified anddescribed above may be varied, and that the order of steps may beadapted to particular applications of the techniques disclosed herein.All such variations and modifications are intended to fall within thescope of this disclosure. As such, the depiction and/or description ofan order for various steps should not be understood to require aparticular order of execution for those steps, unless required by aparticular application, or explicitly stated or otherwise clear from thecontext.

The methods or processes described above, and steps thereof, may berealized in hardware, software, or any combination of these suitable fora particular application. The hardware may include a general-purposecomputer and/or dedicated computing device. The processes may berealized in one or more microprocessors, microcontrollers, embeddedmicrocontrollers, programmable digital signal processors or otherprogrammable device, along with internal and/or external memory. Theprocesses may also, or instead, be embodied in an application specificintegrated circuit, a programmable gate array, programmable array logic,or any other device or combination of devices that may be configured toprocess electronic signals. It will further be appreciated that one ormore of the processes may be realized as computer executable codecreated using a structured programming language such as C, an objectoriented programming language such as C++, or any other high-level orlow-level programming language (including assembly languages, hardwaredescription languages, and database programming languages andtechnologies) that may be stored, compiled or interpreted to run on oneof the above devices, as well as heterogeneous combinations ofprocessors, processor architectures, or combinations of differenthardware and software.

Thus, in one aspect, each method described above and combinationsthereof may be embodied in computer executable code that, when executingon one or more computing devices, performs the steps thereof. In anotheraspect, the methods may be embodied in systems that perform the stepsthereof, and may be distributed across devices in a number of ways, orall of the functionality may be integrated into a dedicated, standalonedevice or other hardware. In another aspect, means for performing thesteps associated with the processes described above may include any ofthe hardware and/or software described above. All such permutations andcombinations are intended to fall within the scope of the presentdisclosure.

While the invention has been disclosed in connection with the preferredembodiments shown and described in detail, various modifications andimprovements thereon will become readily apparent to those skilled inthe art. Accordingly, the spirit and scope of the present invention isnot to be limited by the foregoing examples, but is to be understood inthe broadest sense allowable by law.

All documents referenced herein are hereby incorporated by reference.

What is claimed is:
 1. A method of configuring a mattress, the methodcomprising the steps of: receiving at least one input relating to afirmness of a mattress; providing a plurality of foam springs includingat least a first foam spring defining a first firmness and at least asecond foam spring defining a second firmness different from the firstfirmness, wherein the first foam spring with the first firmness is afirst color and the second foam spring with the second firmness is asecond color different from the first color; providing a containmentfacility for receiving a pattern of foam springs selected from theplurality of foam springs, the pattern including at least one of each ofthe first foam spring and second foam spring; determining a pattern offoam springs selected from the plurality of foam springs including atleast one of each of the first foam spring and second foam spring to bereceived in the containment facility such that the pattern of selectedfoam springs is operable to provide a firmness configurationcorresponding to the at least one input relating to the firmness,wherein the pattern includes an arrangement of foam springs based onfoam spring color; selecting the first foam spring and the second foamspring from among the plurality of foam springs; and positioning theselected first foam spring and the selected second foam spring withinthe containment facility so as to correspond to the pattern based on thefirst color of the first foam spring and the second color of the secondfoam spring.
 2. A method in accordance with claim 1, wherein theplurality of foam springs each being individually removable andreplaceable in the containment facility.
 3. A method in accordance withclaim 1, further comprising: receiving the selected foam springs in thecontainment facility in a pattern corresponding to the determinedpattern; whereby a mattress is configured to include the containmentfacility with the firmness configuration corresponding to the at leastone input relating to the firmness.
 4. A method in accordance with claim1, wherein: the step of receiving at least one input relating to afirmness of a mattress comprises receiving at least one input relatingto a firmness by a computer; and the step of determining a pattern offoam springs comprises determining by a computer.
 5. A method inaccordance with claim 4, further comprising: outputting from a computera schematic representing the pattern of the plurality of foam springs tobe received in the containment facility.
 6. A method in accordance withclaim 5, wherein: the schematic further represents the containmentfacility and the pattern of the plurality of foam springs arerepresented as positioned within the containment facility.
 7. A methodin accordance with claim 5, wherein: the schematic includes a differentcolor for each spring firmness.
 8. A method in accordance with claim 1,wherein: the plurality of foam springs further includes at least a thirdfoam spring defining a third firmness different from the first andsecond firmness, and wherein the third spring is a third color which isdifferent from the first color and the second color.
 9. A method inaccordance with claim 1, wherein: the plurality of foam springs comprisebarrel shaped foam springs.
 10. A method in accordance with claim 1,wherein: the first foam spring includes a material density differentfrom a material density of the second foam spring.
 11. A method inaccordance with claim 1, further comprising: providing an attachmentfacility for attaching together one or more of the selected foam springsreceived in the containment facility; and attaching together the one ormore of the selected foam springs received in the containment facilityusing the attachment facility.
 12. A method in accordance with claim 11,wherein: the attachment facility comprises a webbing with a plurality ofopenings, the openings removably and replaceably receiving said at leastsome of the selected foam springs.
 13. A method in accordance with claim11, wherein: the containment facility further includes at least one foampanel disposed above or below the selected foam springs when theselected foam springs are received in the containment facility.
 14. Amethod in accordance with claim 13, wherein: the at least one foam panelincludes locators for locating the selected foam springs received in thecontainment facility.
 15. A method in accordance with claim 1, wherein:the firmness configuration provided by the pattern of foam springsincludes a plurality of regions and at least one of the regions has adifferent local firmness than the other regions.
 16. A method inaccordance with claim 1, wherein: the plurality of foam springs aredisposed in the containment facility such that the foam springs with thefirst color and the foam springs with the second color form a colorpattern representing a firmness profile.
 17. A method of configuring amattress, the method comprising the steps of: providing a plurality offoam springs including at least a first foam spring defining a firstfirmness and at least a second foam spring defining a second firmnessdifferent from the first firmness, wherein the first foam spring withthe first firmness is a first color and the second foam spring with thesecond firmness is a second color different from the first color;providing a containment facility for receiving a pattern of foam springsselected from the plurality of foam springs, the pattern including atleast one of each of the first foam spring and second foam spring, thefoam springs each being individually removable and replaceable in thecontainment facility; determining a pattern of foam springs selectedfrom the plurality of foam springs including at least one of each of thefirst foam spring and second foam spring to be received in thecontainment facility such that the pattern of selected foam springs isoperable to provide a firmness configuration, wherein the patternincludes an arrangement of foam springs based on foam spring color;selecting the first foam spring and the second foam spring from amongthe plurality of foam springs; positioning the selected first foamspring and the selected second foam spring within the containmentfacility so as to correspond to the pattern based on the first color ofthe first foam spring and the second color of the second foam spring;modifying the firmness configuration by removing and replacing at leastone of the plurality of foam springs with the first color with one ormore foam springs of varying density with a color different from thefirst color.
 18. A method in accordance with claim 17, wherein: theplurality of foam springs are disposed in the containment facility suchthat the foam springs with the first color and the foam springs with thesecond color form a color pattern representing a firmness profile.